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Related Manuals for Cushman YEAR 2012
Summary of Contents for Cushman YEAR 2012
- Page 1 Owner’s Guide 623527 ISSUED JULY 2011...
- Page 2 WELCOME Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Guide. This guide contains the information that will assist you in maintaining this highly reliable vehicle. Some illustrations may show items that are optional for your vehicle. This guide covers the operation of several vehi- cles;...
- Page 3 GASOLINE POWERED VEHICLE SHUTTLE 4X STARTING MODEL YEAR 2012 Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specifications. Such modifications can cause serious personal injury or death. E-Z-GO Division of Textron, Inc. pro- hibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehi- cle.
- Page 4 FOREWORD Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated.
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Page 5: Table Of Contents
TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SECTION PAGE NO. SAFETY....................................1-1 GENERAL SPECIFICATIONS............................. 2-1 INTRODUCTION.................................. 3-1 OPERATING PROCEDURES.............................. 4-1 MAINTENANCE................................... 5-1 Page iii... - Page 6 TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: Page iv...
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Page 7: Safety
SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. SAFETY................................. 1-3 NOTICES, CAUTIONS, WARNINGS, AND DANGERS..................1-3 GENERAL ................................1-4 GENERAL OPERATION ............................1-5 MAINTENANCE .............................. -
Page 8: Safety
SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 1 - 2... -
Page 9: Notices, Cautions, Warnings, And Dangers
SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. - Page 10 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. The exhaust emissions of this vehicles’...
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Page 11: General
SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. GENERAL All vehicles can be used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible to anticipate and warn against every possible combination of circumstances that may occur. -
Page 12: Maintenance
SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. • apply service brake to control speed on steep grades • maintain adequate distance between vehicles. • reduce speed in wet areas •... -
Page 13: Labels And Pictograms
SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LABELS AND PICTOGRAMS 35962G01 35962-G01 Maximum weight in basket is 25 lbs. (11 kg). Excess weight may cause injury resulting from vehicle instability and/or frame damage. - Page 14 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD XXX lbs.
- Page 15 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. CLEAN UP GASOLINE DO NOT EXPOSE SPILLS WITH WATER BEFORE STARTING TO FLAME ENGINE UNLEADED DO NOT GASOLINE DISPOSE OF BATTERIES...
- Page 16 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. KEEP CLEAR OPERATE HAND OR FROM FINGERS CAN DRIVERS SIDE BE TRAPPED ONLY POSITION KEEP ARMS AND LEGS POSITION WITHIN VEHICLE HEADLIGHTS...
- Page 17 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ENGINE CRANKING START POSITION REAR DIFFERENTIAL LOCK SWITCH PULL HANDLE UP TO ENGAGE PARK BRAKE FRONT DIFFERENTIAL LOCK SWITCH. WARNING READ OWNER'S MANUAL BEFORE PULL HANDLE UP,...
- Page 18 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 1 - 12...
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Page 19: General Specifications
GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. SHUTTLE 4X Vehicle Specifications..........................2 - 3 SHUTTLE 4X Vehicle Dimensions........................... 2 - 4 SHUTTLE 4X Vehicle Incline Information and Turning Diameter ................. - Page 20 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 2 - 2...
- Page 21 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. MODEL: SHUTTLE 4X TYPE: GAS POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No: 619213 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki Overhead valve...
- Page 22 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 49.0 in. (125.0 cm) 6.0 in (15.0 cm) 78.0 in. 65.5 in (166.0 cm) (198.0 cm) 107.0 in (272.0 cm) Front 38.0 in.
- Page 23 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TURNING CLEARANCE DIAMETER SHUTTLE 4X 20.3 ft (7.1 m) 2 - 5...
- Page 24 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 2 - 6...
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Page 25: Introduction
INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. FEATURES..................................3-3 General Information ....................................3-3 Key Switch / Headlight Switch..................................3-3 Low Oil Pressure Indicator Light................................. 3-4 Fuel Gauge ......................................... - Page 26 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 3 - 2...
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Page 27: Features
INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. FEATURES General Information If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’... -
Page 28: Fuel Gauge
INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 3. FUEL GAUGE The fuel gauge (if equipped) will either be located on the dash panel (electric) or directly on the fuel tank (mechani- cal). -
Page 29: Front Seats
INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 9. Front Seats The split bench front seat is designed for one occupant on each side of the center console. 10. -
Page 30: Cup Holder
INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 15. Cup Holder A cup holder is provided for convenience of both the driver and passenger. 16. Steering Wheel The steering wheel located in front of the driver seat is used to steer the vehicle. - Page 31 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 3 - 7...
- Page 32 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 3 - 8...
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Page 33: Operating Procedures
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. SERIAL NUMBER LOCATION ............................4-3 BEFORE INITIAL USE ................................ 4-4 OPERATING THE VEHICLE ............................... 4-4 Run-in.......................................... - Page 34 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 4 - 2...
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Page 35: Serial Number Location
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SERIAL NUMBER LOCATION Two serial number and manufacture date code plates are on the vehicle. One is placed on the body below the front, driver side of the seat. -
Page 36: Before Initial Use
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. BEFORE INITIAL USE Read and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle and its equipment as well as how to use it safely. -
Page 37: Run-In
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. To reduce the possibility of severe injury or death resulting from improper vehicle operation, the following warnings must be observed: Refer to GENERAL SPECIFICATIONS for seating capacity. -
Page 38: Cold Starting
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Oil dipsticks are unique to this model vehicle. Do not interchange oil dipsticks between models. The oil should be changed in accordance with the Periodic Service Schedule while the engine is warm. See SERVICE AND MAINTENANCE for checking oil level and changing oil procedures. -
Page 39: Coasting
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Do not hold vehicle on hill by using accelerator and engine. This will cause premature and excessive wear to drive train components. -
Page 40: Battery
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Fuel 1" Min. (2.5 cm) Fueling BATTERY Excessive use of accessories may drain the battery and leave insufficient reserve to start the vehicle. The vehicle uses a combination starter/generator to both start the engine and charge the battery. -
Page 41: Volt Power Outlet
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 12 VOLT POWER OUTLET Overuse of accessories may drain the battery and leave insufficient reserve to start the vehicle. A 12 volt power outlet, rated at 15 amps, is located left side of the key/light switch 12V Power Outlet... -
Page 42: Manual Lift Bed
OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. vehicle and/or cause the vehicle to tip over. Use extra care when operating loaded vehicle. Do not permit any one to ride in the load bed. Do not drive the vehicle with the load bed raised or with the tailgate unsupported. - Page 43 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Gas Strut with Tether Cable Never fill a gas can in the bed of a vehicle. Static discharge could ignite gasoline vapor and cause an explosion.
- Page 44 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 4 - 12...
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Page 45: Maintenance
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. VEHICLE CLEANING AND CARE ............................5-5 Vehicle Cleaning ......................................5-5 COMMON SENSE OPERATION ............................5-6 ENVIRONMENTAL CONCERNS............................ - Page 46 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. LUBRICATION ..................................5-23 SPARK PLUGS .................................5-23 PROLONGED STORAGE..............................5-24 PERIODIC SERVICE SCHEDULE .............................5-25 CAPACITIES AND REPLACEMENT PARTS ........................5-27 HARDWARE ..................................5-27 5 - 2...
- Page 47 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 5 - 3...
- Page 48 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 5 - 4...
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Page 49: Vehicle Cleaning And Care
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. VEHICLE CLEANING AND CARE Vehicle Cleaning To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer. -
Page 50: Common Sense Operation
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. COMMON SENSE OPERATION To prevent severe injury or death, observe the following: Never transport loaded firearms on or in vehicle Check that firearms are unloaded with the safety engaged and are properly secured with muzzle pointing in a safe direction before operating vehicle. -
Page 51: Repair
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. REPAIR Some servicing operations may require the front wheels, the rear wheels, or the entire vehicle to be raised. To reduce the possibility of severe injury or death from a vehicle falling from a jack: Be sure the vehicle is on a firm and level surface. -
Page 52: Wheels And Tires
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Lifting The Vehicle Flat Portion of Frame Center of Front Axle Outside End of Rear Axle View from Underside of Vehicle WHEELS AND TIRES A tire explosion can cause severe injury or death. -
Page 53: Wheel Installation
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel. -
Page 54: Light Bulb Replacement
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LIGHT BULB REPLACEMENT Inside of Cowl Headlight Casing To reduce the possibility of premature bulb failure, do Screw not touch new bulbs with bare fingers. -
Page 55: Transporting Vehicle
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. If the vehicle battery has become discharged, it must be charged using a 12 volt charger that is rated at 10 amps or less. -
Page 56: Service And Maintenance
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. If the vehicle is to be transported at highway speeds, the sun top must be removed and the seat bottom secured. When transporting vehicle below highway speeds, check for tightness of hardware and cracks in sun top at mounting points. -
Page 57: Routine Maintenance
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ROUTINE MAINTENANCE To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures, extreme dust/debris conditions, or frequent use with maximum load. - Page 58 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Remove the dipstick and wipe off the entire area with a lint free cloth. Insert the dipstick fully into the dipstick hole and remove. Examine the level of the oil on the dipstick. Maximum Oil Level Fill Cold Engine For Hot Engine...
- Page 59 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. The selection of oil is dependent upon the service that the vehicle will perform. Most vehicles require 10W-30 oil, whereas vehicles used at capacity or near capacity load applications will utilize 10W-40 oil after a break-in period of 100 hours.
- Page 60 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Inspect the filter. Make sure the ‘O’ ring is not left on the engine surface. Be careful of hot oil when drained. It may be hot enough to burn you severely Drain the oil by removing the drain plug found at the rear of the engine base.
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Page 61: Starter/Generator Belt Tension
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. As a final check, check the oil level again with the vehicle on level ground. Like all liquids, oil increases in volume when warm. -
Page 62: Battery Cleaning
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Tighten the starter/generator pivot bolt. BATTERY CLEANING To reduce the possibility of damage to vehicle or floor, neutralize acid before rinsing battery. To reduce the possibility of damage to electrical components while cleaning, do not use a pressure washer. -
Page 63: Brakes
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. soda) and clear water shown below. In addition to the battery, special attention should be paid to metal components adjacent to the battery which should also be sprayed with the sodium bicarbonate (baking soda) solution. -
Page 64: Periodic Brake Test For Mechanical Brakes
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Periodic Brake Test For Mechanical Brakes Dry, Level, Clean, Paved Surface Accelerate To Maximum Speed Latch Parking Brake Line or Marker and Take Foot Off Pedal... -
Page 65: Rear Axle
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. At least once a year, (or more often under adverse conditions) the cooling system should be cleaned. Cleaning will assure an adequate supply of air to the cooling fins. -
Page 66: Air Cleaner Inspection And Replacement
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Fill / Check Plug Drain Plug AIR CLEANER INSPECTION AND REPLACEMENT The air cleaner unit on the vehicle is a dry unit. Do not use oil on the filter element or any part of the unit. To aide instal- lation and sealing, petroleum jelly may be applied to back side of cover tabs and each side of filter seal. -
Page 67: Lubrication
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LUBRICATION Do not use more than three (3) pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components. -
Page 68: Spark Plugs
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Fouled spark plug is indicated by a wet, black appearance. This could be caused by a dirty air filter element or other restrictions in the air intake system. -
Page 69: Periodic Service Schedule
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PERIODIC SERVICE SCHEDULE Check Clean, Adjust, etc. Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for this vehicle. - Page 70 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Check for leaks at tank, cap, system lines, filters, pump, carburetor FUEL SYSTEM Check system lines for cracks/deterioration ...
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Page 71: Capacities And Replacement Parts
MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. CAPACITIES AND REPLACEMENT PARTS Fuel Tank / Fuel 6.0 gal (22.5 liters) / 87 Octane Min. Engine Oil 1.4 US qt (1.3 liters) Oil Filter P/N 26591-G01... - Page 72 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 5 - 28...
- Page 74 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of...